1967 E Type roadster (TR)
Total Team CJ restoration


 
 

 
Specification (briefly) for this project is as follows:

Total Team CJ restoration featuring significant performance and reliability upgrades, a 370 HP Stage Two 4.7 L engine, Borrani wheels, etc. This car will be finished in British Racing Green with Tan Suffolk & Turley hides.

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Update report - December 10, 2016

Unpacking your beautifully re-plated chrome...





















The doors and boot lid have been reinstalled and adjusted following application of the sprayable polyester. At this stage the panel fit has been finalized and you can see how all the gaps will look on the finished car.



Panel fit is spectacular throughout the car












Rear bottom corner of right side of bonnet










Right hand upper door panel gaps
Lower rear corner of passenger door










Lower rear corner of driver's door
Lower front corner of driver's door





With the bodywork (filler and block) stage completed, your car has now been primed with Spies Hecker 3508 Raderal sprayable polyester.






















Lead loading the rear quarters and front cowl..



Note heater box is trial fitted as part of the
bonnet installation
Filing lead on the front cowl










Right hand cowl now has lead applied
Starting to take shape after filing











All the panel gaps are looking good





Oscar has been busy trimming and fitting your alloy bonnet....



New engine frames installed












Both wings will be trimmed to fit










Oscar checking straightness after hammering over
edge beading











Bonnet fit now starting to take shape
Trial fitting mudguards





We have now removed the monocoque from the rotisserie and placed it on a roll-around frame jig. The next task will be to install the new engine frames and fit the new CJ aluminum bonnet.




Preparing to install the engine side frames










Trial fitting rear lights and license plate chrome
Keeping good company in the CJ Coachworks




Oscar has been busy installing your new floors, after carefully rust proofing all the enclosed box sections with Wurth Body Wax prior to spot welding the floors into place.





Wurth Body Wax is sprayed in all box sections
that will be enclosed by the floors










The body wax will help prevent for decades to come
Left and right hand floors are spot welded along
the center line










Spot welding the rear floor brace in position



































Floors are clamped in place for welding























Literally hundreds of spot welds secure the new floors
to the main monocoque
Trial fitting the outer sills











About to spot weld the outer sills in place




Lots of progress in the Coachworks...


























































































































Cutting out rusted section of inner cowl
Trial fitting replacement repair panel























Rust holes up beneath LH A pillar






















Cracks found around engine stabilizer
bracket











Drilling out spot welds holding bracket
to firewall











Crack cannot be ignored at such an important
structural part of the firewall











Cutting out the corroded section











Trial fitting replacement repair panel
New stabilizer bracket fabricated










Acid washing inner/enclosed surfaces
Tack welding replacement panel in position










TIG weld next
Repair now invisible after metal finishing










Antenna hole will be filled























Unusual view of new boot latch being
trial fitted























All inner box sections are thoroughly rust proofed












Trial fitting new boot lid















We have now wrapped this Stage Two engine rebuild and look forward to seeing how it performs on the chassis dyno in a few months time. We typically see about 380 HP and 430 ft/lbs of torque with our 4.7L CJ Stage Two rebuilds. That's more torque than a Ferrari 458 Italia - in a car weighing less than 2,500 lb!



Preparing to install the oil pan











Not just a pretty face, this engine will put out around
380HP and 430 ft/lbs of torque!





Putting the finishing touches to another 4.7L CJ Stage Two engine rebuild.













































We have now finished the block machine work and we are about to begin the final assembly.



Torque plate cylinder honing in progress
Surfacing the block with front timing chain installed










Balancing flywheel and pressure plate
Balancing your billet stroker crankshaft











Laying out forged Carrillo connecting rods and
custom forged CJ pistons, etc











Final assembly underway!





The following sequence of photographs show Oscar fabricating a new inner support panel for the upper license plate panel. Unfortunately the original panel was completely rotten and new panels are not available, hence the need to fabricate one from scratch.




Removing the rear license plate support panel











A new panel had to be fabricated from scratch











Trial fitting the new panel











Not much left at the back of the car at this point!










Trial fitting license plate panel
Unfortunately your boot lid is also rusty
and will be replaced





Oscar has been busy cutting out corroded metal and fabricating replacement panels for the IRS chassis legs and beneath the windscreen pillars. He has made excellent progress in the last few weeks!






































































































































































































































































































































































Body restoration underway today!









Restoration of your seats now virtually complete.

































Lots of progress in the machine shop, interior trim restoration about to get underway.




Base-line flow testing the head
Machining out old seats










Surfacing gasket areas
Porting in progress (exhaust port)










Machining 5 angled valve job












Front of head prior to sanding and polishing











Surfacing the deck










Rebuilt head now ready for assembly











Beautiful tan Suffolk & Turley hides





I am pleased to report that we now have your Stage 2 (4.7L) engine rebuild underway.




Removing the cylinder head











Crank will be replaced with a billet stroked unit











Oil pan had several cracks that will require welding

































Disassembling the head











Head has extensive shrapnel damage











Measuring head warpage - will require a cam
saddle align hone
Several chambers will require significant repair























Baseline flow testing prior to port work










Cylinder head weld repairs underway






Cutting out floors with the plasma cutter. Click on the large image below for a short video clip.
























Blasting the car back to bare metal has unfortunately exposed some fairly extensive damage, as well as some pretty shoddy sheet metal repairs. The car was obviously quite rusty prior to being painted, with several corroded areas being covered up with bondo or crudely patched. There is also some old accident damage evident around the rear lamp panels.













































































































































A sample of your Nickel plating and powder coating...





















Just some of the goodies that go into a Team CJ Stage Two rebuild...



Some of the component parts of a Team CJ
Stage Two engine rebuild
Billet stroker crank in foreground




We now have your E Type completely disassembled and will have the sheet metal blasted back to bare metal in the next few days.



Time to tear the car down and see what lurks
beneath the shiny paint











Panel gaps are poor, and the car clearly has a great
deal of bondo throughout the body











Engine and transmission removed











Time to remove the interior
Cutting away outer sills reveals patched
inner sills










LH inner sill has been crudely patched with a flat
piece of sheet metal











Car now on a rotisserie blasting jig







We will have this exciting project underway in the next few weeks!



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